Method of making a flush type overhead door



Sept. 24, 1968 c. D. LANDOW ETAL 3,402,457

METHOD OF MAmNG A FLUSH TYPE OVERHEAD DOOR Filed June 25, 1966 5Sheets-Sheet l 2 2a, l 7a' 45 C5 la,

#Y @www Sept 24, 1968 c. D. LANDow ETAL 3,402,457

METHOD OF MAKINGA FLUSH TYPE OVERHEAD DOOR Filed June 23. 1966 5Sheets-Sheet 2 INV ENTORS Char/es ando# 9L Jeanette Lana/0W Sept. 24,1968 C. QLANDQW ETAL 3,402,457 METHOD OE MAKING A FLUSH TYPE OVERHEADDOOR 5 Sheets-Sheet L" Filed June 23,V 19.66

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Unted States Patent Oce 3,402,457 Patented Sept. 24, 17968 3,402,457METHOD F MAKING A FLUSH TYPE OVERHEAD DOGR Charles D. Landow andJeanette Landow, both of 735 Kappock St., Bronx, N.Y. 10463 Filed June23, 1966, Ser. No. 559,758 4 Claims. (Cl. 29-428) This inventionconcerns an improved method of making a flush type door constructionespecially intended for articulated overhead plywood doors such as usedin garages, warehouses and the like, and to the method of making thesame.

It is the principal object of this invention to provide a weather-typegarage made of plywood in which the edges of the plywood are enclosed bythe frame of the door section and protected thereby from moisture whichcauses the peeling of the plywood laminations.

It is another object of the present invention to provide an articulatedsectional door construction which can be manufactured rapidly and easilyassembled by relatively unskilled personnel, and in a manner differentfrom that done heretofore.

It is another object of the invention to provide such a doorconstruction from plywood which is Weather tight and water tight,attractive in appearance, light in weight and more economical tomanufacture than prior sectional doors.

Each section in the door construction has a single rectangular plywoodpanel as its principal body member. This panel is the basis for thestrength of the door as well as its water-tight structure. Frames arefitted around the panels, and hinges are attached to the frames ofadjacent door sections. The panels are applied to both sides of the doorsections.

According to a modification of the invention, the end frame rails arerabbeted and the ends of the panel are seated in the rabbeted portionsand secured thereto whereby the ends of the panel are weatherproofed.

B-roadly, the invention comprises sectional door construction, eachsection composed of a rectangular-shaped wooden panel having framemembers which are fitted along the long sides thereof and bracing railsacross the ends and intermediate the ends on one surface thereof, all ofthe frame members according to the method involved being fitted to theplywood panel rather than making the frames and fitting the panelsthereafter to them. The long edges of the panel lit in rabbeted portionsof the frame members whereby the edges of the panel are protectedagainst chipping or separating and preventing of ,moisture from gettinginto the plies of the panel and warping the panel.

In assembling a door section, the side frame members are fitted againstthe long side edges of the plywood panel, with the panel seating in therabbeted portions of the frame members. The panel is then nailed to therabbeted portions of the frame members. The unit is then turned over andthe bracing rails tted between the side frame members and secured byfastening elements spanning the junctures between the rails and framemembers.

In the accompanying drawings forming a material part ofthis disclosure:

FIGURE 1 is a front elevational view of a sectional door constructionembodying the invention, parts being shown broken away.

FIG. 2 is an enlarged rear elevational view thereof.

FIG. 3 is an enlarged vertical sectional view taken on line 3 3 of FIG.2.

FIG. 4 is a top perspective view of a top or a bottom door section of adoor construction such as shown in FIG. 1.

FIG. 5 is a top perspective view of a complementary intermediate doorsection of which there may be two or more. i

FIG. 6 is a top disassembled and collective perspective viewillustrating a step in Athe manufacture of the door section of FIG. 5 orof FIG. 4, the long side rails or frame members being brought to theside edges of the plywood board.

FIG. 7 is a rsimilar view showing the next step of the rail assembled tothe edges of the board and being brad nailed thereto.

FIG. 8 is a view showing the assembled board and rails turned upsidedown and the short frame pieces being assembled on the board between therails with corrugated fasteners as a final step.

FIG. 9 is a fragmentary top perspective view of a door section embodyinga modified form of the invention, parts being shown broken away whereinthe end short frame pieces are rabbeted to enclose the end edges of theply wood board.

FIG. 10 is a fragmentary sectional view taken on the t line 10--10 ofFIG. 9 and through the rabbeted short frame pieces.

FIG. 11 is a fragmentary front elevational view of a door constructionmade up of the sections of the forms shown in FIG. 9.

FIG. 12 is a fragmentary top perspective view of a double board doorsection, the long side rail being rabbeted on the rear side to similarlyaccommodate a rear board.

FIG. 13 is a cross-sectional view taken on line 13-13 of FIG. 12, and

FIG. 14 is a fragmentary rear elevational view of a door constructionmade up of double board door sections of the form shown in FIGS. 12 and13.

Referring now to FIGS. 1 to 7, inclusive, there is shown iirstarticulated sectional door construction 10, including four plywood doorsections 15, 16, 17 and 18, there being top, bottom and intermediatesections for each door. These door sections comprise forwardly-facingrectangular-shaped plywood panels 20, 21, 22 and 23, respectively. Thepanels are formed of plywood and each is laminated and rectangular inshape. These panels are respectively framed by wooden frames 24, 25, 26and 27.

The frame 24 of lowermost or bottom door section 15 has a wide bottomhorizontal rail 3() with a flat bottom surface 32, FIGS. 3 and 4. Thefront side 33 of rail 30 is rabbeted at 34 defining a ledge 29 on whichseats the bottom edge 35 of plywood panel 20. The front side 33 of thefront side of the rail is 'wide and contains the bottom edge 35 of thepanel protected and removed from the floor moisture.

The frame 24 has a horizontal narrower top rail 36 formed and rabbetedat 38 to define a narrow forwardly exposed ridge 37, and a ledge 39 onwhich seats the upper edge 40 of panel 20. Connecting the upper andlower rails 30 and 36 are three vertical bars or frame pieces 41, 42 and43 spaced apart. Opposite ends of the bars are secured to inner facingedges of rails 30, 36 by corrugated fasteners 44 as best seen in FIG. 2and being applied in FIG. 7. The center bar 42 is equally spacedhorizontally from end bars 41 and 43. Lateral edges 45 of the panel 20overlie bars 41, 43. The edges 45 extend out to and are ush with lateralside faces 46 of bars 41, 43. Nails 48 secure the panel 20 to the rails30 and 36 andthe bars 41, 42. and 43. At upper and lower edges of thepanel 20 may be applied waterproof sealing cement 50, FIG. 3. It w-illbe apparent that in the door section 15, the panel 20 serves as themajor structural frontal member and the frame 24 serves only as backingwhose members are held in rectangular configuration by the panel 20.

The intermediate door section 16 is similar in construction to door V15as shown in FIGS. l to 7. In the door section 16, the frame 25 builtabout panel 21 has vertical bars 41a, 42a and 43a joined to lower andupper rails 30a, 36a by corrugated fasteners 44a. The lower rail 30a andupper rail 36a` have forwardly facing rabbets 34a, 38a in which seatlower and upper edges respectively of panel 21.

The bottom surface of rail 30a is formed `with a rabbet 54 formed in thetop of rail 36 in frame 24. This provides a run-off channel C1i for anyrainwater which may fall on the vertical door assembly. This channelalso facilitates folding movements of the doors with respect to eachother when the door assembly is drawn up to a horizontal position forclearing a doorway in which the door will be mounted. Hinges 55 are usedto secure the doors pivotally together. A further rabbet 54a is formedat the top of rail 36a. This rabbet faces a rabbet 5211 in the bottomrail 30h of frame 26, to define a second channel C2.

Door section 17 is formed like door section 16, FIGS. 3 and 4 so that nofurther explanation of this door is required. The uppermost door 18 hasa wide rail 36C at the top and narrower rail 30e at the bottom. Verticalbars 41e, 42e and 43e join the rails 30C and 36C, FIG. 2. Panel 23overlies the frame 27 and is secured thereto by nails 48. Channel C3 isdefined between facing rabbets in the upper surface of upper rail 36hand the bottom surface of lower rail 30C. A wide ridge 33C is exposed atthe top of the door. The entire door assembly is easily and quicklyassembled with the several hinges placed on the rear faces of the door.

Our improved method of assembling of these door sections is illustratedin FIGS. 6 to 8, inclusive. According to the invention, the long siderail frame members are first brought to the long parallel side edges ofthe panel 21 as indicated by the arrows in FIG. 6, and the long edges ofthe panel positioned or seated in rabbets 34a and 38a and between theridges 33a and 37a of the rail frame members. The panel is then fastenedin position by driving the nails 48 thereinto as shown in FIG. 7. Nextthe panel and attached frame 'members are turned over and the bracingbars or pieces 41a, 42a and 43a are placed in position and fastened tothe side frame members by driving the corrugated fastening elements 44atherein and across the joint between the bars and long frame members asshown in FIG. 8. FIG. shows the door section returned to the uprightfront position.

In FIGS. 9, and 11 a modified form of door section 16a is shown whichdiffers from the door section 16 merely in that the end bars 41a and 43aare rabbeted as indicated at 28a, to receive and protect the end edges45a of the panel 21a as well as the long edges of the panel areprotected. A center bar 42a is located between the end bars andsimilarly secured to the long rails or frame members 30a and 36a.

FIG. 11 illustrates a door construction 10 made up of sections 16a, 17aand similar constructed bottom and top sections a and 18a. In doorconstruction 10' and bars 41a and 43a are formed with a rabbet 28a todeiine ledges 61, 63 on which lateral vertical edges 45a of the panelsrest. Ridges 67, 68 on the end bars liank the end edges 45a of thepanel. The bottom and top rails 30a and 36a of each door frame have therabbets 28a delining horizontal ledges 70, 72 which are continuous andcoplanar with ledges 61, 63. Thus, the horizontal and vertical edges ofeach door panel is enclosed in a rectangular frame defined by ledges 61,63, 70 and 72. Any spaces existing between the edges of the door panelsand the adjacent ridges can be sealed by a suitable caulking compound orsealing cement to render the door section water tight.

In FIGS. l2, 13 and 14, a double door section 16a is shown. This doorsection 16a differs from the door section 16 of FIGS. l to 7 in that theside frame members 30a and 36a' are yrabbeted on both sides thereof, andin addition to the panel 21 at the top, another panel 21a is providedand fastened in position at the bottom so that the door section isclosed on both sides by the panels 21 'and 21a. The door sections willbe assembled in the same manner that the other doors are except that thehinges will be applied to the opposite ends of the sections over theends of the panels.

The various doors described are light in weight, easy to construct, andeconomical to manufacture. Nevertheless, they provide longer, moresatisfactory service than prior articulated doors having individual,recessed panels, They are attractive in appearance due to their fiushfront construction. Also, they are stronger and more watertight. Theywill not splinter, warp or crack with continued use, since they arewater-tight at their edges.

While we have illustrated and described the preferred embodiments of ourinvention, it is to be understood that we do not limit ourselves to theprecise construction herein disclosed and that various changes andmodifications may be made within the scope of the invention as definedin the appended claims.

What is claimed is:

1. A method of manufacturing a door section for an articulated sectionaldoor construction consisting of the steps of positioning long side railwooden frame members underneath the long edges of a rectangular shapedwooden panel, the side frame members being rabbeted, fastening the longedges of the panel to the rabbeted portions of the side frame members,inverting the attached panel and side frame members and while invertedfitting and fastening bars between the side frame members.

2. A method of manufacturing a door section for an articulated sectionaldoor construction as defined in claim 1, wherein the step of fasteningthe panel to the side frame members consists of driving rows of nailsthrough the long side edges of the panel into the rabbeted portions `ofthe side frame members.

3. A method of manufacturing a door section for an articulated sectionaldoor construction as defined in claim 1, wherein the step of fasteningthe cross rails to the side frame members consists of driving metalfastening elements into and across the joint between the side framemembers and the abutting cross rails.

4. A method of manufacturing a door section for an articulated sectionaldoor construction as defined in claim 1 wherein the step of fasteningthe panel to the side frame members consists of driving rows of nailsthrough the long side edges of the panel into the rabbeted portions ofthe side frame members and wherein the step of fastening the cross railsto the side frame members consists of driving metal fastening elementsinto and across the joint between the side frame members and theabutting cross rails.

References Cited UNITED STATES PATENTS 1,672,273 6/1928 Morris 144--3131,703,452 2/1929 Morris 144-313 2,585,961 2/1952 Norquist 29-428 XTHOMAS H. EAGER, Primary Examiner.

1. A METHOD OF MANUFACTURING A DOOR SECTION FOR AN ARTICULATED SECTIONALDOOR CONSTRUCTION CONSISTING OF THE STEPS OF POSITIONING LONG SIDE RAILWOODEN FRAME MEMBERS UNDERNEATH THE LONG EDGES OF A RECTANGULAR SHAPEDWOODEN PANEL, THE SIDE FRAME MEMBERS BEING RABBETED, FASTENING THE LONGEDGES OF THE PANEL TO THE RABBETED PORTIONS OF THE SIDE FRAME MEMBERS,INVERTING THE ATTACHED PANEL AND SIDE FRAME MEMBERS AND WHILE INVERTEDFITTING AND FASTENING BARS BETWEEN THE SIDE FRAME MEMBERS.